Plastic Extrusion Service

As a leading China plastic extrusion manufacturer, Kusla provides plastic extrusion services at a competitive price. we have different kinds of plastic extrusion manufacturing technologies, such as Acrylic extrusion , Polycarbonate extrusion , ABS extrusion ,PVC extrusion as well as other plastic fabrication capabilities. Contact Kusla to find out more today!

  • customize plastic extrusion for your products such as plastic sheet, plastic profile, plastic rod, plastic pipe, plastic tube, plastic films, etc.
  • Extrusion by a wide range of plastic materials.
  • One-stop solution, supported by Second fabrication capabilities

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Plastic Extrusion Specifications & Capabilities

We Specialized in the production of all kinds of plastic extrusion products. It includes extruded PVC profiles, extruded PP profiles, extruded PE profiles, extruded ABS profiles, extruded PMMA lampshade profiles, extruded acrylic lens, extruded LED PC profiles, two-color extrusions, all kinds of slides, circuit guides and other engineering plastics.

MaterialsWe specialize in extruding a wide range of plastic materials, including PVC, HDPE, LDPE, ABS, and many more.
Profile TypesWe offer extrusion services for various profile types, such as solid profiles, hollow profiles, and custom shapes.
Maximum Profile SizeOur extrusion capabilities allow for profiles with maximum dimensions of up to 24 inches in width and 12 inches in height.
Wall ThicknessWe can extrude profiles with wall thicknesses ranging from 0.020 inches to 0.500 inches.
LengthWe can extrude profiles in customized lengths, tailored to your specific requirements.
TolerancesOur extrusion process ensures tight tolerances within ±0.010 inches.
Surface FinishWe provide extruded profiles with a smooth, glossy surface finish, ready for further processing or application.
Color OptionsWe offer a wide range of standard and custom color options for the extruded profiles.
Secondary OperationsIn addition to extrusion, we provide various secondary operations such as cutting, drilling, punching, and more.
Quality ControlWe have a comprehensive quality control process in place to ensure the extruded profiles meet industry standards.
VolumeOur extrusion services cater to both small and large volume production needs.
CustomizationWe offer customization options for profiles, including co-extrusion, embossing, printing, and specific end treatments.

Plastic Extrusion Advantages

  1. Continuous production
  2. High production efficiency
  3. Wide application range
  4. Simple production operation
  5. can complete the comprehensive processing of different technological processes
  6. Simple equipment investment, low cost

Plastic Extrusion Materials

  • Polypropylene Plastic Material

  • PET Plastic Material

  • Nylon Plastic Material

  • HDPE Plastic Material

  • ABS Plastic Material

  • Polycarbonate sheet

    Polycarbonate Plastic Material

  • PVC Plastic Material

  • Acrylic Plastic material

Kusla Plastic Extrusion Services

Kusla can customize your plastic extrusion profiles. include PVC, polycarbonate, HDPE, LDPE extrusion temperature, PVC corner, nylon extrusion, FRP, etc.

And we can offer plastic film, sheets, pipes, and rods. The materials for these products include PP, PE, HDPE, PVC, PVC foam, polycarbonate, polyethylene, ABS, PET, nylon, etc.

Kusla is a one-stop solution for plastic fabrication. We can handle cutting to size, CNC milling, polishing, painting, silk screening, and assembling into the final products for you.

Application Cases

FAQS about plastic extrusion

Plastic extrusion is a manufacturing process in which raw plastic is melted and formed into a continuous profile with a constant cross-section. The process starts by feeding plastic material (pellets, granules, flakes or powders) from a hopper into the barrel of an extruder, where a screw transports, melts, and pressurizes it. The melted material is then forced into a die to shape it, and then cut to length or cooled. The process can produce products such as pipe/tubing, weatherstripping, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings, and wire insulation.

Different Principle

   The principle of plastic injection is to inject the plastic into a closed mold core, obtain a fixed shape product after cooling in the mold.

   The principle of plastic extrusion is to make the plastic go through a certain shape of mold, then obtain a certain shape product after cooling in another machine.

Different Characteristics Of Plastic Injection Molded And Plastic Extrusion Molded Products

  Plastic Injection molding:

  • Injection molding of various shapes of complex plastic products;
  • The structure size of the product is more accurate and the surface quality is better;
  • Injection molding products can be standardized and serialized;

 plastic Extrusion molding:

  • Continuous production process, can extrudate any length of plastic parts, high production efficiency;
  • The mold structure is also simple, convenient manufacturing and maintenance, less investment, fast results;
  • Wide application range, simple operation equipment, less investment, quick effect, sanitary production environment, low labor intensity, suitable for mass production.

To know what material you will need for plastic extrusion, you will need to consider the following factors:

  • The desired shape and cross-section of your product
  • The mechanical and thermal properties of your product
  • The cost and availability of the material
  • The environmental impact and recyclability of the material

Some of the common materials used for plastic extrusion are:

  • Polypropylene (PP): A versatile and economical material that is resistant to chemicals, heat, and fatigue
  • Polyethylene (PE): A flexible and durable material that is easy to process and has good impact strength
  • Polyvinyl chloride (PVC): A rigid and fire-resistant material that is widely used for pipes, tubing, and profiles
  • Acrylonitrile butadiene styrene (ABS): A tough and impact-resistant material that can be colored and textured easily
  • Polycarbonate (PC): A transparent and high-performance material that has excellent optical and mechanical properties

You can also use other materials such as nylon, acrylic, polystyrene, and thermoplastic elastomers depending on your specific requirements.

The standard lead times for plastic extrusion depend on several factors, such as:

  • The complexity and size of the product
  • The availability and cost of the material
  • The design and fabrication of the extrusion tooling
  • The quantity and quality of the order
  • The post-production services required, such as cutting, splicing, taping, etc.

the average lead time for plastic extrusion can range from 2 to 12 weeks, but it may vary depending on the specific requirements and conditions of each project. It is best to consult with your plastic extrusion service provider to get an accurate estimate of the lead time for your product.

Extrusion tooling is the term used to describe the die and other components that are used to shape the material in the extrusion process. The die is a metal block with a hole or opening that matches the desired cross-section of the product. The material is forced through the die by a plunger or a screw, creating a continuous profile. The die can be customized to produce different shapes and sizes of products, such as pipes, tubes, rods, wires, films, sheets, etc. Extrusion tooling also includes other parts that help control the flow, temperature, pressure, and cooling of the material, such as feeders, heaters, breakers, mandrels, calibrators, etc. Extrusion tooling is an important factor that affects the quality, cost, and efficiency of the extrusion process.

The cost of extrusion tooling depends on several factors, such as:

  • The size and complexity of the die
  • The type and quantity of the material used for the die
  • The design and fabrication time and labor required for the die
  • The maintenance and replacement costs of the die

According to some sources, the tooling costs for extrusion dies can range from $400 to $2,000, depending on the application and specifications. Some manufacturers may refund or waive the tooling costs if a certain amount of products are purchased within a certain period of time. Extrusion tooling costs are usually lower than other manufacturing processes, such as injection molding.

There are different types of plastic extrusion based on the following criteria:

  • The type of extruder used: There are three basic types of plastic extrusion machinery: single screw, multiple screw, and ram extruders. Single and multiple screw extruders are the most commonly used, but ram extruders (which feature a ram or plunger instead of a screw) are also useful for plastics that don’t melt well with a screw, such as PTFE and UHMW.
  • The type of die used: The die is the metal block with a hole or opening that shapes the material into the desired cross-section. There are different types of dies for different products, such as solid dies, hollow dies, spider dies, porthole dies, bridge dies, etc.
  • The type of product produced: The product is the final output of the extrusion process, which can have various shapes and sizes. Some common types of products are pipes, tubes, rods, wires, films, sheets, profiles, coatings, etc.

Some examples of specific types of plastic extrusion processes are:

  • Blown film extrusion: This process produces thin plastic films by blowing air into a molten tube of plastic and expanding it like a balloon. The film can be used for packaging, bags, liners, etc.
  • Sheet/film extrusion: This process produces flat plastic sheets or films by passing the material through a flat die and then cooling it on a roller. The sheet or film can be used for thermoforming, laminating, printing, etc.
  • Profile extrusion: This process produces complex shapes with a fixed cross-section by passing the material through a custom die and then cooling it in a water bath or air stream. The profile can be used for window frames, door frames, railings, etc.
  • Coextrusion: This process produces products with multiple layers or colors by combining two or more materials in a single die. The coextruded product can have enhanced properties or aesthetics.

The extruder is a machine that heats and pushes a material through a die to create a shape with a cross-sectional profile. The extruder works by following these steps:

  • The raw plastic material (pellets, granules, flakes or powders) is fed from a hopper into the barrel of the extruder.
  • The material is gradually melted by the mechanical energy generated by turning screws and by heaters arranged along the barrel.
  • The molten polymer is then forced into a die, which shapes the polymer into a shape that hardens during cooling.
  • The extruded product is then cut to length or cooled further by a water bath or air stream.

The extruder can be used for various purposes, such as producing pipes, tubes, films, sheets, profiles, coatings, etc.. The extruder can also be customized to produce different shapes and sizes of products by using different types of dies and materials.

Some of the advantages of plastic extrusion are:

  • Low cost: Compared to other plastic molding processes, plastic extrusion has a low cost and is more efficient. The extrusion process uses thermoplastics that undergo repeated melting and hardening, allowing the waste to be reused. The extrusion machines operate continuously and reduce the chances of inventory shortage. The tooling costs for extrusion are also lower than other processes.
  • Flexibility: Extrusion can produce a wide range of products with different shapes and sizes by using different types of dies and materials. Extrusion can also produce products with multiple layers or colors by using coextrusion techniques. Extrusion can also produce products with atypical cross-sections that may be difficult to achieve by other methods.
  • Post-extrusion alterations: Since the plastic remains hot when it is removed from the extruder, it can be further manipulated by using rollers, shoes, dies, or other devices to change its shape as needed. This can enhance the properties or aesthetics of the product.

Some of the challenges of plastic extrusion are:

  • Expansion: Once the hot plastic is removed from the extruder, it may expand due to the release of pressure and heat. This is called die swell. It can be difficult to predict and control the exact degree of expansion, which may affect the accuracy and consistency of the product dimensions.
  • Mechanical properties: Extruded plastics may have lower mechanical properties and strength than other plastic products due to the orientation and degradation of the polymer chains during the extrusion process. This can limit the applications of extruded plastics in some industries that require high-performance materials.
  • Product limitations: Extrusion can only produce products with a fixed cross-section and a continuous length. This may restrict the design and functionality of some products that require complex shapes or discrete sizes. Extrusion may also require additional post-processing steps, such as cutting, bending, drilling, etc., to achieve the desired product features.

Some of the applications of plastic extrusion are:

  • Pipes and tubing: Plastic extrusion can produce pipes and tubing with various diameters, lengths, and wall thicknesses. These products can be used for plumbing, drainage, irrigation, gas supply, etc.
  • Wire insulation: Plastic extrusion can produce thin plastic films or coatings that can cover electrical wires and cables to provide insulation and protection.
  • Window and door profiles: Plastic extrusion can produce complex shapes with a fixed cross-section that can be used for window frames, door frames, sliding tracks, etc.
  • Blinds: Plastic extrusion can produce flat or curved slats that can be used for window blinds or shutters.
  • Weatherstripping: Plastic extrusion can produce flexible strips or seals that can be used for weatherproofing doors, windows, or other openings.
  • Windshield wipers and squeegees: Plastic extrusion can produce rubber-like materials that can be used for windshield wipers or squeegees.

You can improve the quality of your plastic extrusions by following some of these tips:

  • Adjust feed throat temperature: The feed throat temperature should be set to prevent the material from sticking or bridging in the hopper. It should also be low enough to avoid premature melting of the material before it reaches the screw.
  • Maintain a consistent regrind form: The regrind material should be uniform in size, shape, and moisture content to ensure proper feeding and melting. It should also be free of contaminants and foreign materials.
  • Cool screws when processing polymers to minimize degradation: The screws should be cooled by water or air to prevent overheating and degradation of the polymer. This can also improve the output and quality of the extrusion.
  • Use only treated water in your closed-loop, water-cooled barrel system: The water used for cooling the barrel should be treated to prevent corrosion, scaling, and fouling of the system. This can also improve the heat transfer and efficiency of the extrusion.
  • Use low-cost fillers or recycled plastics: You can reduce your material cost by using low-cost fillers such as calcium carbonate or recycled plastics. However, you should be careful about the quality and compatibility of these materials, as they may affect the properties and performance of your extrusion.

To design a plastic extrusion profile, you need to consider the following steps:

  • Define your product requirements: You need to specify the function, performance, appearance, and dimensions of your product. You also need to consider the environment, load, stress, and temperature that your product will be exposed to.
  • Choose your material: You need to select a suitable plastic material that meets your product requirements and is compatible with the extrusion process. You also need to consider the cost, availability, and recyclability of the material.
  • Design your profile: You need to create a 2D or 3D drawing of your profile that shows the cross-section and length of your product. You also need to follow some basic guidelines to minimize extrusion problems, such as:
    • Use generous internal and external radiuses on all corners; the smallest possible radius is about 0.5 mm.
    • Maintain uniform wall thickness (important!).
    • Make walls no thicker than 4 mm.
    • Make interior walls thinner than exterior walls (for cooling).
    • Minimize the use of hollow sections.
  • Design your die: You need to design a metal block with a hole or opening that matches the cross-section of your profile. You also need to consider the material flow, pressure drop, die swell, and cooling rate of the extrusion.
  • Test and optimize your design: You need to test your design using simulation software or prototype tooling to check for any defects or problems in the extrusion process. You also need to optimize your design by making adjustments or modifications as needed.

Some of the common defects in plastic extrusions and how to avoid them are:

  • Die swell: This is the expansion of the extruded product due to the release of pressure and heat when it exits the die. It can affect the accuracy and consistency of the product dimensions. To avoid die swell, you can reduce the die temperature, increase the die land length, or use a material with a lower melt elasticity.
  • Melt fracture: This is the irregular or rough surface of the extruded product due to the instability of the material flow in the die. It can affect the appearance and performance of the product. To avoid melt fracture, you can reduce the melt temperature, increase the die temperature, or use a material with a lower viscosity.
  • Shark skin: This is a fine roughness or waviness on the surface of the extruded product due to the stick-slip phenomenon in the die. It can affect the appearance and quality of the product. To avoid shark skin, you can reduce the screw speed, increase the melt temperature, or change the screen pack.
  • Fish eyes: These are small circular defects on the surface of the extruded product due to contamination or moisture in the material. They can affect the appearance and strength of the product. To avoid fish eyes, you can check and clean the material and screen for contamination, dry the material properly before using, or reduce the melt temperature.
  • Bubbles: These are air pockets or voids inside or on the surface of the extruded product due to trapped air or moisture in the material. They can affect the appearance and integrity of the product. To avoid bubbles, you can dry the material properly before using, reduce the melt temperature, or reduce the screw speed.
  • Warpage: This is the distortion or deformation of the extruded product due to uneven cooling or stress. It can affect the shape and function of the product. To avoid warpage, you can increase the cooling rate and length, balance the die according to the wall thickness, or use a material with a lower shrinkage rate.

To choose the right extrusion die for your product, you need to consider the following factors:

  • The type of product: You need to determine whether your product is a solid, hollow, or semi-hollow shape, and choose the corresponding type of die accordingly. Solid dies produce products with no enclosed voids or openings, such as rods, beams, or angles. Hollow dies produce products with one or more voids, such as tubes or complex profiles. Semi-hollow dies produce products with partially enclosed voids, such as channels or U-shapes.
  • The type of material: You need to select a suitable material for your product that is compatible with the extrusion process and the die design. You also need to consider the properties of the material, such as viscosity, melt elasticity, shrinkage rate, thermal expansion, etc., and how they affect the flow, pressure, temperature, and cooling of the extrusion.
  • The type of die: You need to design a metal block with a hole or opening that matches the cross-section of your product. You also need to consider the shape and size of the die opening, the length and angle of the die land (the area where the material exits the die), the die swell (the expansion of the extruded product due to pressure and heat release), and the die exit velocity (the speed of the material leaving the die).
  • The type of tooling: You need to select the appropriate tooling to support and enhance the die performance. The tooling includes parts such as feeders, heaters, breakers, mandrels, calibrators, etc., that help control the flow, temperature, pressure, and cooling of the material in the die.

Some of the environmental impacts of plastic extrusion are:

  • Greenhouse gas emissions: Plastic extrusion contributes to greenhouse gas emissions from the production of plastic materials, the use of fossil fuels for energy, and the incineration or degradation of plastic waste. According to a study by CIEL, plastic production and incineration in 2019 emitted about 850 million metric tons of greenhouse gases, equivalent to 189 coal-fired power plants. Plastic waste in landfills and oceans also releases methane and ethylene as it breaks down, which are potent greenhouse gases.
  • Air pollution: Plastic extrusion can cause air pollution from the emissions of volatile organic compounds (VOCs), particulate matter (PM), nitrogen oxides (NOx), sulfur oxides (SOx), and other pollutants from the extrusion machines, heaters, and incinerators. These pollutants can affect the health and well-being of workers and communities near the extrusion facilities.
  • Water pollution: Plastic extrusion can cause water pollution from the discharge of wastewater, chemicals, and plastic particles from the extrusion process. These pollutants can contaminate the water sources and aquatic ecosystems, affecting the quality and availability of water for human and animal consumption. Plastic waste in oceans can also harm marine life by entanglement, ingestion, or toxicity.
  • Soil pollution: Plastic extrusion can cause soil pollution from the accumulation of plastic waste in landfills or illegal dumping sites. Plastic waste can leach harmful chemicals into the soil, affecting the fertility and productivity of the land. Plastic waste can also fragment into microplastics that can be ingested by soil organisms or enter the food chain.

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